[0001] The present invention relates to a wire management apparatus for use in a wire harness
fabrication machine for fabricating electrical harnesses. More particularly, it relates
to a wire guide apparatus for reciprocably changing the centerline spacings of adjacent
wires in a discrete wire cable segment between at least two distinct pitches.
[0002] The present invention includes harness fabricating machines including wire management
apparatus of the present invention.
[0003] Harness fabrication machines are widely used today. Generally, harness fabricators
are employed to terminate a plurality of wires in the form of either insulation-clad
discrete wires or ribbon cable to multicircuit electrical connectors. An illustrative
harness fabrication machine for automated mass-termination of discrete wires to insulation
displacement contact connectors is described in US-A-4,235,015.
[0004] Wire guide means for positioning wires in proper alignment for termination in harness
fabrication equipment are also known. For example, in US-A-4,372,041 a wire comb is
mounted adjacent the termination station. The comb includes a number of parallel wire
receiving channels through which the ends of a plurality of insulation clad wires
are threaded. The wire comb is reciprocably moveable in an axial direction with respect
to the wires. Prior to termination, the wire comb is moved towards the termination
station, thereby combing, i.e. straightening and spacing, the wire ends in proper
alignment so that a termination blade can readily mass-insert the wire ends into the
insulation displacement slots of a connector. The wire guide apparatus disclosed in
this patent does not provide a structure which permits the centerline spacing of the
wires to be changed from one pitch to another, for example, to provide a continuous
harness fabrication operation, wherein a variety of different connectors can be used
having differing terminal centerline spacings, without interrupting production.
[0005] US-A-4,476,628 describes a connector jig apparatus which includes a stacked linear
array of web splitting fingers including a central rectangular cut-out portion adapted
to receive an insulation displacement connector. The web-splitting fingers extend
above the top surface of a nested connector on opposed sides and terminate in free
ends defined by tapered cutting edges. The jig is used with flat ribbon cable to sever
the web between individual cable conductors, and as the cable is forced downwardly
toward the connector, the fingers spread apart, thereby re-spacing the separated individual
conductors to a wider centerline spacing appropriate for termination to the connector
terminals. In an alternate embodiment, the jig apparatus can accomplish sequential
termination of identical pitch connectors which differ from each other in terms of
circuit size, i.e., circuit number. The jig apparatus described in this patent cannot
be used to accomplish smooth, continuous wire spacing transitions for discrete wire
from a closer spacing to a wider spacing and back again, for the purpose of terminating
the wires to different connectors which contain terminals set at different centerline
spacings.
[0006] It is an object of the present invention to provide, for use in a harness fabrication
machine, an apparatus for changing the centerline distance of a plurality of generally
coplanar wires.
[0007] In accordance with this object, the present invention provides for use in a harness
fabrication machine, an apparatus for changing the centerline distance of a plurality
of generally coplanar wires comprising:
a wire guide including a plate member having a wire engaging edge and a corresponding
number of open-ended wire guide channels, each extending inwardly from the edge to
a closed end, the closed end of said channels being spaced apart by a centerline spacing
different from the centerline spacing of said open ends in said edge, said wire guide
being reciprocally moveable between a first position wherein the open ends are engaged
with the wires adjacent the edge, to a second wire receiving position wherein said
wires are disposed at the closed ends, whereby actuation of the wire guide causes
movement of the wires within their respective channels to alter the centerline spacing
thereof.
[0008] The plate member of the wire guide apparatus may engage the wires, one wire in a
corresponding channel. The plate member may be actuated perpendicularly with respect
to the longitudinal axes of the wires to alter the centerline spacing between them.
The plate member may be actuated between the first and second positions by any conventional
actuation means, such as for example an air cylinder actuator or a solenoid actuator
to name a few. In use of the apparatus the plate member may be positioned adjacent
a termination station of a wire harness machine and arranged to be actuated between
the first and second positions in response to positioning movement of a connector
nest at the termination station. At least two connector nests may be provided in the
harness machine. Positioning of one nest or the other at the termination station may
then be made effective to raise or lower the plate member, respectively, to present
appropriately spaced wires to the termination station for termination to the connector
that each particular nest carries.
[0009] The plate member may be provided with opposed channel ends which are configured to
align the engaged wires, at the first and second positions of the plate member, respectively,
so that the wire spacings correspond to conventional but different connector terminal
centerline spacings. Accordingly, the centerline spacing of adjacent wires imparted
by the open channel ends in the first position may be 0.100 of an inch and at the
closed ends in the second position may be 0.118 of an inch, for example, or 0.125
of an inch.
[0010] A wire guide apparatus of the present invention as described in the immediately preceding
paragraph permits a production run of 0.100 inch pitch wire harnesses to be performed
by actuating the wire guide to the first position and by feeding 0.100˝ center connectors
from a first connector feed to the termination station for termination to the wires.
Thereafter, if a production run of 0.118˝ pitch harnesses is desired, the plate number
is actuated to the second position and 0.118˝ center connectors are fed to the termination
station from a second connector feed. The wire guide apparatus permits the changeover
in production to occur in a substantially smooth, continuous automated manner which
does not require prolonged downtime for the harness fabrication machine.
[0011] In addition, a wire guide apparatus of the present invention permits continuous fabrication
of pitch transition double ended and daisy-chain type wire harnesses. Accordingly,
by alternating connector feeds and reciprocating the wire guide between first and
second positions as appropriate prior to termination, a single wire harness having
a plurality of different pitch connectors terminated to the same discrete wire cable
segment, can be prepared in automated harness fabrication equipment.
[0012] The pitch transition wire guide apparatus of the present invention is a relatively
inexpensive apparatus for reciprocably changing the centerline spacing of adjacent
wires of a discrete wire feed in a harness fabrication machine to advantageously
increase the capabilities of the machine both in terms of the number and kinds of
harnesses the machine can produce.
[0013] One way of carrying out the present invention in both its apparatus and machine aspects
will now be described by way of example with reference to drawings which show one
specific embodiment of the apparatus and one specific embodiment of machine incorporating
the apparatus for continuously automatically fabricating pitch transition wire harnesses
including a common plurality of wires terminated to different pitch connectors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014]
FIG. 1 is a perspective view of the plate member of a pitch transition wire guide
apparatus of the present invention, shown in a first position in engagement with a
plurality of insulation clad wires;
FIG. 2 is a perspective view of the plate member shown in Fig. 1 in a second wire
engaging position wherein the centerline spacing of adjacent wires has been altered
to a different pitch;
FIG. 3 is an exploded perspective view of the mounting frame and plate member of a
pitch transition wire guide apparatus of the present invention incorporating the plate
member shown in Figs. 1 and 2;
FIG. 4 is a front elevation view of the assembled plate member and mounting frame
shown in Fig. 3;
FIG. 5 is a perspective view of a pitch transition double ended wire harness; and
FIGS. 6 to 13 schematically illustrate a termination sequence in a machine employing
the apparatus of Figs. 1 to 4 in producing a pitch transition wire harness as shown
in Fig. 5.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0015] Referring now to Figs. 1 to 3 the apparatus comprises a wire guide 10 including a
plate member 12 having a wire engaging edge 14 and a corresponding number of open
ended wire guide channels 16. Each channel 16 extends inwardly from edge 14 to a closed
end 20. Opposite closed ends 20 are open ends 17 defined at edge 14. Closed ends 20
are spaced apart by a centerline spacing Y which is different from the centerline
spacing X of the opposed open ends 18 defined in the wire engaging edge 14.
[0016] As shown in Figs. 1 and 2 a plurality of insulation clad discrete wires 22 are each
slideably received within a corresponding channel 16. Plate member 12 is positioned
perpendicularly with respect to the longitudinal axes of wires 22. Wire guide 10 is
reciprocably moveable between a first position as shown in Fig. 1 wherein open ends
18 of channels 16 are in engagement with wires 22 adjacent edge 14 and a second wire
receiving position as shown in Fig. 2 wherein wires 22 are disposed at closed ends
20. In use of the apparatus, an actuation means, not shown, is provided for moving
the wire guide between first and second positions. As has been mentioned above, the
actuation means may include an air cylinder actuator or a solenoid actuator connected
to plate member 12 in a manner which is effective to reciprocably move it between
the first and second positions shown in Figures 1 and 2 respectively.
[0017] Plate member 12 is provided with elongate leg projections 24 and 26 extending away
from wire engaging edge 14 from opposed sides of plate member 12. Leg projections
24 and 26 provide extensions of the plate member which are engageable with a connector
nest associated with a harness fabrication machine. Movement of the connector nest
causes the nest to engage leg extensions 24 and 26 to effectively move or actuate
the plate member 12 between the first and second positions.
[0018] The wire guide 10 is made of a low surface friction, hard material, e.g. stainless
steel. Channels 16 are provided in plate member 16 by wire electro-discharge machining
methods (wire EDM) because the centerline spacing of channels 16 and the narrow gauge
of the channel widths are generally too small to be provided by other forming methods,
such as casting of metal plate member 12. Wire EDM methods also provide smoothly curved
continuous transition sections 28 for channels 16 between the opposed ends 18 and
20.
[0019] As shown in Figs. 1, 2 and 3, the closed ends 20 of channels 16 are spaced on adjacent
centerlines Y that are wider apart than the adjacent centerline spacing X provided
at the open ends 18 of channels 16. The channels 16 are each designed to receive a
particular gauge wire and are arranged in plate member 12 so that ends 18 and 20 impart
a different selected centerline spacing to the wires upon movement of plate member
12 with respect to the wires to the first and second positions of plate member 12.
Plate member 12, as shown in Figures 1 and 2 have mounting apertures 30 and 32 for
securing the plate member to an actuator means or to a mounting frame assembly 34,
shown in Figs. 3 and 4.
[0020] Referring now to Fig. 3, a split mounting frame assembly 34 is provided which is
adapted to receive and maintain plate 12 in a perpendicularly reciprocable relationship
with respect to a plurality of wires 22. More particularly, frame assembly 34 includes
a bottom half 36 including a rear block portion 38 and a forward portion 40. Block
portion 38 includes a forward edge 42 and a top surface 44. A wire receiving recessed
slot 46 is defined in top surface 44. The rearward end 48 of recessed slot 46 is provided
with upstanding projections 51 forming grooves 50. A pair of mounting guide posts
52 and 54 extend upwardly from top surface 44.
[0021] Forward portion 40 comprises a generally U-shaped member including a long yoke 56
and a pair of opposed short legs 58 and 60. Forward portion 40 is shown fixedly mounted
to forward edge 42 of block portion 38 by means of mounting screws 62 extending through
leg members 58 and 60 into threaded apertures provided in edge 42 of block 38. Forward
portion 40 cooperates with forward edge 42 to define a vertically extending plate
receiving passageway 64 adjacent the forward end of bottom half 36. The upper surface
of yoke 56 includes a cut out area 66 aligned with wire slot 46 and partly defining
the forward opening 68 of slot 46.
[0022] Split frame assembly 34 also comprises a top half 70 including a complementary rear
block portion 72 and top forward portion 74. Top block portion 72 is provided with
a pair of spaced mounting apertures 76 and 78 which are adapted to be engaged on mounting
posts 52 and 54 when top half 70 and bottom half 36 are assembled together. A screw
receiving aperture 80 extends through block 72 which is adapted to register with a
threaded aperture 82 in bottom block member 38; to permit the assembled parts of frame
34 to be fixed together, also by means of a screw 62. The inner facing surface 84
of top block 72 is also provided with raised wire stuffing projections 86 which are
designed to cooperate with grooves 50 in block 38 to urge wires 22 entering wire slot
46 into grooves 50.
[0023] The top forward portion 74 is mounted to the front edge of top block 72 in a manner
similar to front portion 40 and is adapted to cooperate with bottom half 36 to further
define plate receiving passageway 64 and forward wire slot opening 68 in frame assembly
34.
[0024] As shown in Figure 3, plate 12 is fixedly attached at its upper end to a stabilizer
plate 88 by means of mounting screws 62. Stabilizer plate 88 extends perpendicularly
rearward from wire guide plate 12 and is provided with a pair of guide apertures 90
adapted to be slidably received on mounting guide posts 52 and 54. Mounting guide
posts 52 and 54 and passageway 64 cooperate with apertures 90 and plate member 12
to effectively limit movement of guide plate 12 in a substantially perpendicular direction
with respect to wire receiving slot 46.
[0025] The assembled wire guide apparatus 10 is shown in Figure 4 in a rest position. As
shown in Figure 4, forward portions 40 and 74 cooperate to define the forward opening
68 to wire receiving slot 46. Wire guide plate 12 extends within plate receiving passageway
64 in a manner which perpendicularly intersects wire slot 46. The wire guide channels
16 cooperate with wire slot 46 to define openings through which wires can be advanced
through the wire guide apparatus 10 from rear to front.
[0026] In the rest position shown in FIG. 4, plate member 12 is in a lowered position with
respect to mounting frame 34 such that stabilizer plate 88 rests on the upper surface
of top block 72 and projecting leg portions 24 and 26 of plate member 12 extend for
a distance below the bottom surface of bottom half 36. In this rest position, the
wire slot 46 intersects the wire guide channels 16 in plate member 12 adjacent closed
ends 20. This corresponds with what has earlier been referred to as the second position
of the wire guide plate 12. A portion of a connector nest on its way to a termination
station engages the lower ends of leg projections 24 and 26 of plate 12. As the connector
nest is further moved upwardly into its position at a termination station, the nest
will simultaneously cause the wire guide plate 12 to move upwardly in passageway 64
with respect to frame assembly 34 to the aforementioned first position of the plate
member. In the process, wires engaged within channels 16 will slide in the channels
to assume the centerline spacing imparted by open channel ends 18 in the plate member
12. Reciprocal movement of the guide plate 12 within passageway 64 between the first
and second positions is effective to change the centerline spacing of the wires exiting
through forward slot opening 68 between the two discrete spacings provided at the
open end and closed ends of channels 16.
[0027] The apparatus 10 is intended for use in a harness fabrication machine. Many different
kinds of harness fabrication machines are commercially available and are in use. Generally,
all include a termination station whereat a plurality of wires are terminated to the
terminals of a multicircuit connector. Connector feeding and positioning means are
provided to locate connectors one at a time at the termination station. Wire feeding
means are provided to advance an aligned set of wires from a wire supply to the termination
station. Termination means are provided at the termination station for individually
or mass-inserting the set of wires into the insulation displacement slots of the
terminals of the connector. The harness fabricators also generally include a cutting
means to sever a completed wire harness from the advancing wire supply and ejectment
means.
[0028] Some harness fabricators assemble pre-cut wire lengths in parallel spaced relationship
and move the array of wires to a termination station. A connector is attached at one
end and the wires are rotated on a turntable to present the opposed wire ends for
termination. In other fabricators, two termination stations are provided and opposed
wire ends are simultaneously terminated with connectors.
[0029] In still other harness machines, double-ended or daisy-chain harnesses are prepared
from a single wire supply and single termination station by terminating a first connector
to wire ends. Thereafter, the connector is moved out of the termination station, pulling
the wires along with it, to present a second portion of the wires at the termination
station for attachment to a second connector. Other modified variations are known
for terminating one and two part connectors to discrete wires.
[0030] Generally, the wire guide apparatus 10 can advantageously be positioned adjacent
a termination station and used in any harness fabrication machine wherein it is desired
that the connector feed contain a series of differing connectors whose terminals are
located on different centerline pitches. In these applications there is a need to
change the spacings between adjacent wires of a wire feed in order to terminate them.
[0031] The wire guide apparatus 10 can also be used in a harness fabrication machine to
permit fabrication of a pitch transition wire harness 92 as shown in FIG. 5. Wire
harness 92 includes a first multicircuit insulation displacement connector 94 disposed
at one end thereof. Connector 94 includes a dielectric housing 96, including an upper
surface 98 including five spaced apart wire receiving slots 100. Five insulation displacement
contact terminals 102 are mounted in connector housing 96 such that their insulation
displacement slots 104 are aligned with wire receiving slots 100 at the upper surface
98 of the housing 96. For purposes of illustration, the centerline spacing of adjacent
insulation displacement slots 104 of connector 94 is manufactured to be 0.118˝. Connector
94 can be commonly referred to as a 118 center connector.
[0032] Pitch transition wire harness 92 additionally includes a second multicircuit insulation
displacement connector 106 shown at the opposed end of harness 92. Connector 106 also
comprises a dielectric housing 108 having a configuration different from housing 96
but also including an upper surface 110 including wire receiving slots 112 having
terminals 114 mounted therein. Terminals 114 also include five insulation displacement
slots 116 aligned with slots 112. Connector 106 is manufactured to provide a centerline
spcing between adjacent insulation displacement slots 116 of 0.100 inch. Connector
106 may be referred to as a 100 center connector.
[0033] Pitch transition harness 92 additionally includes five parallel spaced apart insulation
clad wires 22 terminated at each end to insulation displacement connectors 94 and
106. The wire harness 92 is adapted for making electrical connections between two
external components, not shown, which include electrical contacts set at 118 and
100 center spacing, respectively. A pitch transition wire harness such as 92 may be
prepared in a smooth, continuous fully-automated manner using modified conventional
harness fabrication equipment which incorporates wire guide apparatus 10.
[0034] Referring now to Figs. 6 to 13 the operation of the wire guide apparatus 10 in a
harness fabrication machine, for making pitch transition wire harness 92 is shown.
[0035] More particularly, the wire guide apparatus 10 is illustrated in a harness fabrication
machine 118 illustrated schematically in Figs. 6 to 13. Harness fabrication machine
118 illustrated in the figures is of the type described in US-A-4,235,015. Generally,
this type of harness fabrication machine 118 is designed to mass terminate a coplanar
parallel spaced array of discrete wires in respective insulation displacement contact
terminals of a connector at a termination station, generally designated at 120 in
the figures.
[0036] Wires 22 are fed from a wire supply through a wire feed, not shown, which advances
wires 22 toward termination station 120 in a parallel spaced coplanar fashion. A connector
feed is provided which generally includes a connector supply such as a feeder bowl
apparatus or the like, not shown, which advances individual multicircuit connectors
along a delivery track to a delivery station. A connector shuttle means is provided
which advances connectors from the delivery station to a connector nest which is movable
to position the connector at termination station 120. Reciprocable termination blades
are provided above the termination station. The blades are lowered to force the wires
into respective insulation displacement slots within the connector terminals in a
simultaneous mass insertion stroke. Thereafter, the connector nest is moved to a second
station 122 withdrawing the terminated wires therewith to present a second portion
of discrete wires 22 at termination station 120 for termination to a second connector.
The second connector is fed to termination station 120 by means of a second connector
nest which positions the second connector under extended wires 22 which in turn lie
under the termination blade. Wire cutting means are also provided at termination station
120 to sever a completed wire harness 92 from the discrete wire feed supply and ejection
means are provided for ejecting completed harness 92 out of fabrication machine 118
to a storage or shipment container or the like.
[0037] Referring now to FIG. 6, a modified harness fabrication apparatus 118 is shown. Harness
fabrication apparatus 18 has been modified to include two independently actuable termination
blades 124 and 126. Harness fabricator 118 also is provided with two independently
actuable connector nest structures 128 and 130. Termination blade assembly 124 is
dedicated to termination of a 118 pitch connector 94 shown in FIG. 5. Termination
blade 124 includes a plurality of wire insertion blades 132 aligned to force insulation
clad wires 22 into insulation displacement slots 104 of terminals 102 through the
wire receiving slot openings 100 in the top surface 98 connector 94.
[0038] Termination blade assembly 126 includes a plurality of wire insertion blades 132,
as well as, a cable cutting blade 134 adapted to sever an otherwise completed wire
harness 92 from the wire feed. Second termination blade assembly 126 is laterally
reciprocable toward and away the first termination blade assembly 124 in addition
to being vertically reciprocable towards termination station 120. Both blade assemblies
124 and 126 are independently mounted through actuation means 136 to a table member
138.
[0039] Table member 138 includes an upper surface 140 including a wire receiving trough
142. Mounted at the forward end 144 of table 138 immediately adjacent termination
station 120 is a wire guide apparatus 10 as previously described.
[0040] As shown, split mounting frame 34 is mounted at forward end 144 so that the rearward
block portions 38 and 72 are disposed on table 138 and plate passageway 64 and forward
portions 40 and 74 are disposed over the forward edge 144 of the table 138. The double
ended wire receiving slot 46 extending through the split mounting frame assembly 34
is aligned with the wire trough 142 of table member 138. The wire guide plate member
12 is mounted in passageway 64 and is reciprocably moveable in a substantially perpendicular
direction with respect to wire receiving slot 46 and wire trough 142. The leg extensions
24 and 26 of plate 12 extend below the underside surface of table 138. The entire
table apparatus 138 is reciprocable in a vertical direction in a short vertical stroke
as will be more particularly described hereinafter.
[0041] Also shown in FIG. 6 is a second connector nest 130 adapted to receive and position
a 100 center connector 106 shown in FIG. 5. Second connector nest 130 is shown loaded
with a connector 106. Connector nest 130 is mounted to a carrier member 146 which
also is adapted for vertical reciprocable movement with respect to termination station
120 and table assembly 138.
[0042] In the starting position shown in FIG. 6, a plurality of wires 22 are advanced from
a wire supply, not shown, along wire trough 142 in table member 138. The wires enter
the rearward opening of wire slot 46 in split mounting frame assembly 34 and are slidingly
received within grooves 50 in lower rear block portion 38. The raised stuffing projections
86 provided in the top block portion 72 urge wires 22 down into grooves 50 to pre-align
wires 22 so that they each pass through a corresponding guide channel 16 in plate
member 12. In accordance with this apparatus, wires 22 extend through slot 46, passageway
64, channels 16 in plate member 12, and exit from forward slot opening 68 to termination
station 120.
[0043] In the starting position shown in FIG. 6, wire guide plate 12 is shown in its second
or lowered position wherein the individual wires are disposed adjacent the closed
channel ends 20 of plate member 12. Channel ends 20 have been machined in plate member
12 in order to impart a centerline spacing to a predetermined gauge of insulation
clad wires of 0.118 inch. The wires 22 exiting the forward opening 68 in wire slot
46 will advance toward termination station 120 with 0.118 inch spacing between the
wires.
[0044] The beginning of the termination sequence is illustrated schematically in FIG. 7.
As shown in FIG. 7, a first connector nest 128 carrying 118 center connector 94 has
been moved into position termination station 120. The entire table assembly 138 has
been fractionally lowered and leading ends 148 of discrete wires 22 extend from the
front slot opening 68 into the termination station 120 disposed at 0.118 centerline
pitch. Termination blade 124 is shown in its raised position above conductors 22 and
connector 94. In this starting position, second termination blade 126 and second connector
nest 130 are in their starting positions remote from the termination station 120.
In FIG. 7, the wire ends 148 are appropriately positioned above insulation displacement
slots 104 in connector 94.
[0045] FIG. 8 shows the termination step for connector 94, wherein termination blade 124
is actuated toward connector 94 which forces insulated wire leads 148 into the insuation
displacement slots 104 of connector 94.
[0046] The next terminating sequence step is illustrated in FIG. 9, wherein termination
blade 124 is reciprocated upwardly to its rest position and connector nest 128 is
moved axially out of the termination station 120 to second station 122. Movement of
connector nest 128 to station 122 is effective to draw the terminated connector 94
and wires 22 from the wire feed through the wire guide apparatus 10 to present a second
portion of wires 22 at the termination station 120.
[0047] Turning now to FIGS. 10 through 12, the terminating sequence for the second connector
106 is shown. FIG. 10 shows inward reciprocation of termination blade 126 so that
termination blade 126 abuts against termination blade 124. Inward movement of termination
blade 126 to this position places it in overlying alignment with connector 106 nested
within connector nest 130, which is still at this point disposed below termination
station 120.
[0048] After second termination blade 126 has been moved to position above termination station
120, connector nest 130 and carrier 146 is actuated upwardly to move connector 106
into termination station 120. In the process, the upper surface of carrier 146 engages
downwardly extending leg portions 24 and 26 of plate member 12 pushing it up through
passageway 64 until plate member 12 assumes a first position with respect to the plurality
of wires 22 extending through the split frame member 34. In this position, wires 22
are engaged at the open ends 18 of channels 16. Upward movement of plate member 12
has caused the centerline distance between adjacent wires 22 to be changed to 0.100
inch. Carrier 146 also raises table assembly 138 to its original upward position.
The 100 pitch connector 106 is now in termination position at termination station
120, wherein the insulation displacement slots 116 connector 106 are aligned immediately
underneath wires 22.
[0049] Thereafter, as shown in FIG. 13, termination blade assembly 126 is actuated downwardly
in a termination stroke to force wires 22 into the insulation displacement slots 116
mounted in connector 106. Simultaneously wire cutting blade 134 cuts through the wires
22 disposed over a top portion 150 of connector nest 130. Top portion 150 includes
a blade receiving member, not shown, adapted to prevent premature dulling of cutting
blade 132.
[0050] In the process cutting blade 132 is urged against the upper surface of connector
nest 130 to sever the completed terminated harness 92 from the wires 22 to form a
new supply of wire ends 148. After completed wire harness 92 has been severed from
wires 22, ejection means, not shown, move the completed pitch transition cable harness
92 laterally out of the respective connector nest 128 and 130 to a storage container
or a harness delivery track.
[0051] After ejection, the termination cycle is completed by actuating connector nest 130
to its to its original position as shown in FIG. 6. Second termination blade 126 is
outwardly actuated to its initial starting position. In the process of lowering connector
nest 130, plate member 12 of wire guide apparatus 10 is once again lowered to its
second position wherein wire leads 22 are engaged at the closed ends of channel 16.
Thereafter, connector nest 128 is moved to its initial starting position to pickup
another 118 pitch connector 94. Thereafter, the next harness fabrication sequence
can be performed.
[0052] As illustrated schematically in Figures 6 to 13 movement of the connector nest 130
may provide the actuation means for reciprocably moving wire guide plate member 12
between first and second positions to respace the wire ends 148 presented at termination
station 120. The pitch transition imparted to the wires 22 by wire guide apparatus
10 may be smoothly accomplished in the described manner without any machine shutdown
for changeover being required.
[0053] The application and use of the new and improved pitch transition wire guide apparatus
in different types of harness fabrication machines will be readily apparent to those
skilled in this art. If the harness fabrication machine includes more than one termination
station, independently actuable wire guides 10 can be positioned at each one. Moreover,
the wire guide apparatus 10 can be used in harness fabrication equipment for terminating
wires to connectors which do not include insulation displacement type contacts.
1. For use in a wire harness fabrication machine, an apparatus for changing the centerline
distance of a plurality of generally coplanar wires characterized by
a wire guide including a plate member having a wire engaging edge and a corresponding
number of open-ended wire guide channels, each extending inwardly from the edge to
a closed end, the closed ends of said channels being spaced apart by a centerline
spacing different from the centerline spacing of said open ends in said edge, said
wire guide being reciprocably moveable between a first position whereat the open ends
are in surrounding engagement with the wires adjacent the edge to a second wire-receiving
position wherein said wires are disposed at the closed ends,
and actuation means for moving the wire guide between said first and second
positions whereby actuation of the wire guide causes movement of the wires within
their respective channels to alter the centerline spacing thereof.
2. An apparatus as claimed in claim 1 wherein said wire guide includes a mounting
frame having a block member with a plate receiving passageway within which the plate
is reciprocally moveable and an open-ended wire receiving slot perpendicular to and
intersecting the passageway to position and hold said wires so that portions thereof
extend through said passageway prior to actuation of the wire guide.
3. An apparatus as claimed in claim 2 wherein said wire receiving slot further includes
a plurality of grooves, each aligned with a corresponding wire channel in said guide
member.
4. An apparatus as claimed in any preceding claim wherein the centerline spacing of
the closed ends is larger than the centerline spacing of the open ends.
5. An apparatus as claimed in any one of claims 1 to 3 wherein the centerline spacing
of the closed ends is smaller than the centerline spacing of the open ends.
6. A wire harness fabrication machine including an apparatus as claimed in any preceding
claim and actuation means for moving the wire guide between said first and second
positions.
7. A machine for making a wire harness including a plurality of insulation clad wires
terminated in a corresponding number of insulation displacement contacts in a multicircuit
connector comprising:
a termination station whereat said wires are inserted into the contacts of the
connector,
means for positioning the connector at said termination station;
means for feeding the wires to said termination station in an aligned generally
coplanar manner, and at a predetermined centerline spacing; and
termination means at said termination station for terminating the wires in the
contacts characterized by
a pitch controlling wire management means disposed adjacent said termination
station and intermediate the wire feed and the termination station, said wire management
means including a wire guide comprising a plate member having a wire engaging edge
and a corresponding number of open-ended wire guide channels, each extending inwardly
from the edge to a closed end, the closed ends of said channels being spaced apart
by a centerline spacing different from the centerline spacing of said open ends in
said edge, said wire guide being reciprocably moveable in a substantially perpendicular
direction with respect to said wires between a first position wherein the open ends
are in engagement with the wires adjacent the edge and a second wire-receiving position
wherein said wires are disposed at the closed ends, and actuation means for moving
the wire guide between said first and second positions, whereby actuation of the wire
guide is effective to re-position the wires to the centerline spacing provided at
either said first or second positions.